Computational Design of Cost-Effective Oxidation- and Creep-Resistant Alloys for Coal-Fired Power Plants

Increasing the steam temperature of supercritical boilers from 1,000°F to 1,400°F can raise the operating efficiency of next-generation coal-fired power plants from about 32% to about 42%. However, traditional ferritic, austenitic, and nickel-based alloys struggle to meet 1,400°F (and desirably higher temperatures) due to limitations in resistance to creep, oxidation, thermal fatigue and other issues that occur at these elevated temperatures. Hence, a need exists to design and develop novel cost-effective oxidation- and creep-resistant alloys that do not have these performance limitations. This project will implement a systems-based approach to design and develop novel cost-effective oxidation- and creep-resistant alloys for thick-section components of coal-fired power plants. In Phase I, computational models will be used to design novel compositions; prototype ingots of select materials will be fabricated at an intermediate scale; and physical tests will be performed to demonstrate the ability of the new materials to address the creep strength, thermal fatigue, and oxidation resistance requirements. Commercial Applications and other Benefits as described by the awardee: The new alloys should serve as cost-effective oxidation- and creep-resistant materials for coal-fired power plants, enabling higher temperature operation. Higher operating temperatures can increase efficiency and reduce CO2 emission while also enhancing national security, domestic employment, balance of trade, and U.S. GDP